Method and apparatus for packaging non-woven garments

ABSTRACT

A method for containerlessly packaging non-woven safety garments to minimize particulate shedding, including at least partially filling a pressing cavity of a orthorhombic parallelepiped shape with compressible, non-woven safety garments, applying isostatic pressure to the cavity to compact the garments into a compressed mass, wrapping the compressed mass and removing the compressed mass from the cavity. The wrapped compressed mass retains a substantially rectangularly parallelepiped-shape.

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to the field of packaging, andmore specifically to a method and apparatus for providing boxless andregularly shaped stackable packages of safety garments.

BACKGROUND OF THE INVENTION

Safety garments, such as disposable smocks, jumpsuits, gloves, shoecoverings, and hair coverings, are required apparel for the performanceof many jobs. Some of the jobs requiring safety garments are performedin clean room environments, wherein the introduction of foreign mattermust be minimalized. For example, technicians in certain sensitivemedical fields dealing with infectious matter, aerospace researchersassembling interplanetary probes, and material scientists developing andmanufacturing ultrapure materials all wear safety garments in clean roomenvironments. The safety garments perform the dual function ofprotecting the wearer from the potentially hazardous materials he isworking with as well as preventing unwanted matter from the wearer'sperson from contaminating his work product.

Safety garments are typically provided in lots containing a plurality ofidentical safety garments. These lots are typically provided in boxesmade of a structural material such as cardboard, and are shaped asregularly sized rectangular blocks for ease of storage and handling. Thesafety garments are typically packed into these boxes, either by hand orby machine. One drawback of providing boxed safety garments is thatparticulate organic material may from the packaging process and/or fromthe box itself may adhere to the safety garment, thus partiallydefeating the purpose of the clean room environment. Further, the boxesthemselves tend to attract vermin such as rodents and insects that enjoyconsuming organic comestibles such as cardboard packaging. In additionto producing excess packaging particles when consuming the packagingmaterial, such vermin also contribute even more particulatecontamination in the form of carried dirt, shed hair, fecal wastematter, and the like. Thus, cardboard boxes are problematic for thetransport and storage of safety garments intended for clean room use.

One partial solution has been to bag the safety garments in polymer bagsor the like that do not contribute particulate contaminants and do notattract vermin. The problem with this approach is that the bags areinherently irregularly shaped and are thus not easily or convenientlystacked for storage and transport. Another partial solution has been topackage the safety garments in boxes made of inorganic materials, suchas plastics or metal that do not shed particulate contaminants and donot attract vermin. However, such packaging materials are inherentlymore expensive than traditional boxes and cannot be easily broken downfor disposal, contributing even more expense to the enclosed products.

There thus remains a need for a need for an inexpensive packaging systemthat does not contribute particulate contamination, does not attractvermin and may be easily stacked for storage and readily disposed ofafter it has served its purpose. The present invention addresses thisneed.

SUMMARY OF THE INVENTION

The present invention relates to a method and apparatus forcompressively packaging safety garments to form stackable wrappedblocks. Compressible safety garments are placed into a rectangularparallelepiped compression chamber and an isostatic ram operationallyconnected to the compression chamber is inserted thereinto to apply acompression force to the garments. A vacuum pump fluidically connectedto the compression chamber is actuated to reduce the air pressure in thecompression chamber during the compression process, and the resultingcompressed rectangular parallelepiped blocks are wrapped in flexibleplastic wrapping material to yield wrapped rectangular parallelepipedblocks that may be stacked and stored for future use.

One object of the present invention is to provide an improved method andapparatus for packaging safety garments. Related objects and advantagesof the present invention will be apparent from the followingdescription.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a first embodiment apparatus forproducing wrapped compressed blocks of safety garments of the presentinvention.

FIG. 2 is an enlarged partial view of the embodiment of FIG. 1.

FIG. 3 is a schematic view of safety garments being loaded into thecompression chamber of FIG. 1.

FIG. 4 is a schematic view of safety garments being compressed in theapparatus of FIG. 1.

FIG. 5 is a schematic view of a compressed block of safety garments inthe apparatus of FIG. 1.

FIG. 6 is a schematic view of the compressed block of safety garments ofFIG. 5 being wrapped.

FIG. 7 is a perspective view of the wrapped block of safety garments aswrapped in FIG. 6.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For the purposes of promoting an understanding of the principles of theinvention and presenting its currently understood best mode ofoperation, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended, with such alterations and furthermodifications in the illustrated device and such further applications ofthe principles of the invention as illustrated therein beingcontemplated as would normally occur to one skilled in the art to whichthe invention relates.

FIGS. 1-7 schematically illustrate a first embodiment of the presentinvention, a packaging apparatus 10 and method for the containerless orboxless packaging of non-woven garments 12, such as smocks or coverallsmade from spunbond/melt blown/melt blown/spunbond (SMMS) material andthe like. The nonwoven garments are characterized by an associated loosedensity. The packaging apparatus 10 includes a cavity or chamber 14 forcompressing a plurality of safety garments 12 placed thereinto. Thechamber 14 preferably includes a rectangular base 16 with four generallyplanar walls 18 extending perpendicularly therefrom to define anorthorhombic parallelepiped enclosure 14. In some preferred embodiments,the base 16 is a square. The chamber 14 more preferably defines a volumefrom about 4500 cubic inches to about 8100 cubic inches. In somepreferred embodiments, the chamber 14 is a cube.

The chamber 14 is sized to receive an isostatic ram member 20, shown indetail in FIG. 2. The isostatic ram member 20 is operationally connectedto the chamber 14 and is able to move into the chamber 14 to provide acompressive force to the interior of the chamber 14 sufficient tocompress nonwoven safety garments 12 loaded into the chamber 14 andremove substantially all of the entrapped air therefrom. Preferably, aram 20 pressure of about 80 PSI is sufficient to compress the garments12 and facilitate removal of most or all of the entrapped air from thechamber 14. Also preferably, there is sufficient gap between the rammember 20 and the chamber walls 18 to allow air to escape as the rammember 20 is introduced into the chamber 14.

The apparatus 10 preferably further includes a vacuum system 26 forpulling a partial vacuum on the chamber 14 during the compressionoperation. The vacuum system 26 includes a vacuum pump 28 fluidicallyconnected to the chamber 14 such that actuation of the vacuum pump 28reduces the air pressure in the chamber 14. The vacuum system 26 furtherincludes an air conduit 30 pneumatically or fluidically connected to thechamber 14 for at least partially removing the air therefrom, and alsoan enclosure defining a vacuum chamber 32 within which the chamber 14 isdisposed. The vacuum chamber 32 is shown herein schematically, and maybe of any convenient configuration sufficient to allow the generation ofa partial vacuum within the compression chamber 14.

The apparatus 10 further includes means for wrapping a compressed block36 with a flexible nonshedding wrapping material 38 to yield ansubstantially orthorhombic parallelepiped-shaped block of compressedsafety garments 40, such as a polymer sheet, plastic film, or the like.Such means is illustrated schematically herein, and may comprise anyconvenient automated wrapping technology in the art. The polymerwrapping material 38 is preferably a polymer material capable ofsustaining a pressure differential (i.e., vacuum wrapping a bundle ofcompressed garments 12) and is more preferably polyethylene,polypropylene, polyester (such as MYLAR®) or the like. The polymerwrapping material 38 is preferably of sufficient thickness to retard gasleakage thereacross. In the case of a polyethylene wrapping material 38,the preferred sheet thickness is about 4 mils. However, any convenientflexible wrapping material 38 of sufficient thickness to wrap acompressed block 36 sufficiently to retain its substantiallyorthorhombic parallelepiped shape may be selected. Moreover, by wrappingthe block 36 in additional layers, thinner and more deformable wrappingmaterial 38 may be suitable.

In operation, a number of compressible safety garments 12 are preferablyfolded and stacked, and then placed into the chamber 14. Preferably,between about 10 and about 15 pounds of safety garments 12 are placedinto the chamber 14 at once. The chamber is preferably sized to acceptthe stack of safety garments 12 with a minimum amount of excess volume.The interior of the chamber 14 is preferably lined with a polymer orplastic wrapping material 38, such that the safety garments 12 areplaced into the wrapping material 38 in the chamber 14. Alternately, thewrapping material 38 may be applied to the compressed mass 36 after theremoval of the compressed mass 36 from the chamber 14.

Preferably, a partial vacuum is then produced within the chamber 14 andthe safety garments 14 are then isostatically pressed to compact theirvolume and remove entrapped air. However, the compaction process doesnot necessarily require the presence of a partial vacuum and may beperformed at standard air pressure. Preferably, the safety garments arecompacted to a density of between about 2 and about 5 times theirassociated loose density, and more preferably to about 3 times theirloose density. Preferably, a force of between about 50 and about 120 PSIis sufficient to achieve such compression. Typically, the density of acompressed mass 36 is about 0.004 pounds per cubic inch.

The wrapping material 38 is then sealed (the sealing process ispreferably but not necessarily performed under a partial vacuum) and theresulting compressed block 36 is removed from the chamber 14.Preferably, the block 36 is again wrapped with wrapping material 38(i.e., the compressed block of garments 36 is double wrapped) and theouter wrapping 38 is then sealed (preferably heat sealed); alternately,the block 36 may be heat sealed or otherwise sealed after its initialcompression. More preferably, the second application of wrappingmaterial 38 is in the form of a gusset to assist in the retention of thepreferred block shape. The resultant package 40 has the shape of anorthorhombic (preferably rectangular) parallelepiped and retains thatshape during shipping and storage. In one preferred embodiment, thepackage 40 has dimensions of about 16×14×12 inches and has a mass ofabout 11 pounds.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character. It is understood that theembodiments have been shown and described in the foregoing specificationin satisfaction of the best mode and enablement requirements. It isunderstood that one of ordinary skill in the art could readily make anigh-infinite number of insubstantial changes and modifications to theabove-described embodiments and that it would be impractical to attemptto describe all such embodiment variations in the present specification.Accordingly, it is understood that all changes and modifications thatcome within the spirit of the invention are desired to be protected.

1. A method for containerlessly packaging non-woven safety garments,comprising: a) at least partially filling a pressing cavity having apredetermined orthorhombic parallelepiped shape with non-woven safetygarments; b) applying isostatic pressure to the cavity to compact thegarments into a compressed mass; c) wrapping the compressed mass; and d)removing the compressed mass from the cavity; wherein the wrappedcompressed mass is substantially orthorhombic parallelepiped-shaped. 2.The method of claim 1 wherein after a) and before d) a partial vacuum isapplied to the pressing cavity.
 3. The method of claim 1 wherein apartial vacuum is generated in the pressing cavity during c).
 4. Themethod of claim 1 wherein the isostatic pressure is about 80 PSI.
 5. Themethod of claim 1 wherein the pressing cavity is substantially cubic. 6.The method of claim 1 wherein the pressing cavity has the shape of anorthorhombic parallelepiped.
 7. The method of claim 1 wherein thenonwoven garments are formed of a spunbond/melt blown/meltblown/spunbond material.
 8. The method of claim 1 wherein the volume ofthe cavity is at least about 4500 square inches, the mass load of thecavity is about 10 pounds, and the applied isostatic compression forceis about 80 PSI.
 9. The method of claim 1 wherein the compressed mass istwice wrapped.
 10. A method of packaging nonwoven safety garments,comprising: compressing a nonwoven safety garment item having anassociated uncompressed loose density to a compressed densitycorresponding to about 2 to about 5 times the loose density; andmaintaining the safety garment item compressed density by means ofpackaging; wherein the packaging defines a substantially rectangularparallelepiped shape.
 11. The method of claim 10 further comprisingpulling a partial vacuum on the nonwoven safety garment.
 12. The methodof claim 11 wherein the nonwoven safety garment is compressed with aforce of about 80 PSI.
 13. An apparatus for compressively packagingsafety garments to form stackable wrapped blocks, comprising: arectangular parallelepiped compression chamber; an isostatic ramoperationally connected to the compression chamber for applying acompression force thereinto; a vacuum pump fluidically connected to thecompression chamber; and an assembly for wrapping compressed rectangularparallelepiped blocks operationally coupled to the compression chamber.14. The apparatus of claim 13 wherein the isostatic ram is adapted toapply a compressive force of at least about 80 PSI kilograms per cubiccentimeter.
 15. The apparatus of claim 14 wherein the isostatic ram isadapted to apply a compressive force of between about 50 PSI and about120 PSI kilograms per cubic centimeter.
 16. The apparatus of claim 13wherein the compression chamber is has a volume of between about 4500cubic inches and 8100 cubic inches.
 17. The method of claim 13 whereinthe compression chamber is adapted to produce compressed rectangularparallelepiped blocks having dimensions of about 16 inches by about 14inches by about 12 inches.
 18. An apparatus for packaging safetygarments, comprising: a rectangular parallelepiped compression chamber;means for isostatically compressing contents of the compression chamber;means for wrapping the contents of the compression chamber; and meansfor generating a partial vacuum within the compression chamber.
 19. Aboxless stackable block of prepackaged nonwoven safety garments,comprising: a compressed block of nonwoven safety garments; and at leastone layer of polymer wrapping material enclosing the compressed block ofnonwoven safety garments; wherein the at least one layer of polymerwrapping material defines a generally rectangular parallelepiped shape;and wherein the at least one layer of polymer wrapping materials exertsa force onto the compressed block sufficient to maintain compression.20. The block of claim 19 wherein the at least one layer of polymerwrapping material is substantially non-porous.
 21. The block of claim 19wherein the at least one layer of polymer wrapping material ispolyethylene and wherein the at least one layer of polymer wrappingmaterial is about 4 mils thick.
 22. The block of claim 19 wherein the atleast one layer of polymer wrapping material is polyester film.
 23. Theblock of claim 19 wherein the at least one layer of polymer wrappingmaterial includes a plurality of layers.
 24. The block of claim 19wherein one of the plurality of layers is a gusset layer and wherein thegusset layer reinforces the rectangular parallelepiped shape.
 25. Theblock of claim 19 wherein the compressed block of safety garments issubstantially free of entrapped air.
 26. The block of claim 19 whereinthe compressed block has a volume of about 2700 cubic inches and a massof about 10 pounds.